Fluid purification systems and methods

ABSTRACT

Apparatuses and methods for filtering particulates and volatiles from fluid systems. The apparatuses and methods include particulate filter and evaporator sections. The apparatuses and methods may furthermore include a heater disposed at least in part in the evaporator section having a ridge on a surface of the heater. The apparatuses and methods may furthermore include an evaporation tube positioned around the heater having a conically shaped outer surface and a heater safety sensor. The apparatuses and methods may also include an air inlet and an air outlet in the evaporator section.

CROSS-REFERENCE TO RELATED APPLICATIONS

None.

FIELD OF THE INVENTION

The present invention is directed to fluid filtration systems andmethods. In particular, the fluid filtration systems and methods aredirected to systems and methods that remove particulates and volatilesfrom oil and hydraulic fluid systems.

BACKGROUND OF THE INVENTION

Oils and other fluids are used in various applications, including, forexample, lubrication of machinery and to apply hydraulic force tovarious actuators. Such systems may be substantially closed, as in anengine lubrication application, or open, such as in a hydraulic systemhaving a vented tank. In both those systems, the fluids may be replacedfrequently. Such replacement may not be required because the fluiditself is ineffective, but rather because the fluid has become suffusedwith undesirable materials, such as particulates, water, or uncombustedfuel. Thus, it is believed that there is a need for filtration systemsand methods that improve the cleanliness of such fluids to save thecosts of labor and replacement fluids. It is furthermore believed thatthere is a need for filtration systems and methods that improve thecleanliness of such fluids to minimize wasting resources, such as oiland hydraulic fluid, which may continue to be effective once cleaned.

SUMMARY OF THE INVENTION

The present invention is directed to systems, methods and apparatusesfor filtering fluids. In accordance with one form of the presentinvention, there is provided a filtration apparatus having a particulatefilter section and an evaporator section. The filtration apparatus alsoincludes a heater situated at least in part in the evaporator section.The heater may have a surface with a ridge. An evaporation tube having aconically shaped outer surface that is placed around a heater is alsoprovided in an embodiment.

In another embodiment, the present filtration apparatus includes aparticulate filter section, an evaporator section having a heater, and apressure sensor having a switch coupled to the heater wire. The pressuresensor operates to energize or de-energize the heater in thatembodiment.

In yet another embodiment, the present filtration apparatus includes anair inlet and an air outlet in the evaporator section.

The present filtration apparatus provides advantages that may includeimproved fluid heating and volatile removal. The present filtrationapparatus also provides improved safety for the fluid and the systemserved by the fluid.

Accordingly, the present invention provides solutions to theshortcomings of prior fluid filtration systems and methods. Those ofordinary skill in fluid filtration will readily appreciate, therefore,that those details described above and other details, features, andadvantages of the present invention will become further apparent in thefollowing detailed description of the preferred embodiments of theinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated herein and constitutepart of this specification, include one or more embodiments of theinvention, and together with a general description given above and adetailed description given below, serve to disclose principles of theinvention in accordance with a best mode contemplated for carrying outthe invention.

FIG. 1 is a cross-sectional view of an embodiment of a filtrationapparatus;

FIG. 2 is a side view of an embodiment of an evaporation chamber heaterfor an embodiment of a filtration device.

FIG. 3 is a cross-sectional view of an embodiment of an evaporationchamber in a filtration device that may be suitable for use with a smallengine;

FIG. 4 is a cross-sectional view of an embodiment of an evaporationchamber in a filtration device that may be suitable for use with ahydraulic system;

FIG. 5 is a cross-sectional view of an embodiment of a manifold in anembodiment of a filtration device;

FIG. 6 is a cross-sectional view of an embodiment of a fluid samplevalves;

FIG. 7 is an illustration of an embodiment of an engine incorporating afiltration apparatus; and

FIG. 8 is an illustration of an embodiment of a hydraulic systemincorporating a filtration apparatus.

DETAILED DESCRIPTION OF THE INVENTION

Reference will now be made in detail to the preferred embodiments of thepresent invention, examples of which are illustrated in the accompanyingdrawings. It is to be understood that the figures and descriptions ofthe present invention included herein illustrate and describe elementsthat are of particular relevance to the present invention, whileeliminating, for purposes of clarity, other elements found in typicalsystems with which fluid filtration apparatuses and methods areemployed.

Any reference in the specification to “one embodiment” or “anembodiment” means that a particular feature, structure or characteristicdescribed in connection with the embodiment is included in at least oneembodiment of the invention. The appearances of phrases such as “in oneembodiment” in various places in the specification are not necessarilyall referring to the same embodiment. References to “or” are furthermoreintended as inclusive so “or” may indicate one or another of the oredterms or more than one ored term.

FIG. 1 illustrates a cross-sectional view of an embodiment of afiltration apparatus 100. Filtration apparatus 100 includes a filterchamber 102, an evaporator chamber 104, and a filter base 105. Thefilter base 105 may be formed of aluminum or another desired materialand may be formed by extrusion, machining, casting, or another desiredmethod.

The filtration apparatus 100 may be used in various applicationsincluding filtration of lubricants in engines of various types and inpressurized fluid applications such as hydraulic fluid filtration. Oil,hydraulic fluid, or another fluid may pass through the filter chamber102 and the evaporator chamber 104 in series and in either order or maypass through the filter chamber 102 or the evaporator chamber 104individually or in parallel.

The filtration apparatus 100 of FIG. 1 includes an inlet 106 having afilter inlet 107 and an evaporator inlet 109, an outlet 108 having afilter outlet 117, and an inner-chamber opening 111. The filter chamber102 furthermore includes a filter cavity 110, and a filter canister 112.The filter inlet 107, evaporator inlet 109, filter outlet 117, andinner-chamber opening 111 may be individually blocked by caps or plugs127 to create various flow paths through the filtration apparatus 100.

An inlet valve 135 may be coupled to the filtration apparatus inlet 106to control or restrict flow through the filtration apparatus 100, asshown in FIG. 5. An orifice 125 may be placed in the filter inlet 107 toregulate flow through the filtration apparatus 100, for example, whenseries flow through the filter chamber 102 and evaporator chamber 104 isdesired. Alternately, orifices 125 may be placed in the inlet valve 135,filter inlet 107, evaporator inlet 109 or elsewhere as desired.Placement of orifices 125 in each of the inlet valve 135, filter inlet107, and evaporator inlet 109 may act to regulate flow into each of thefilter chamber 102 and evaporator chamber 104 when operating thosechambers in parallel and may further create pressure in the inlet 106 toactuate the pressure switch 148 described hereinafter.

In an embodiment wherein series flow through the filter chamber 102 andthe evaporator chamber 104 is desired, plugs 127 are placed in theevaporator inlet 109 and the filter outlet 117 as shown in FIG. 1. Whenso arranged, fluid passes into the filter cavity 110 through the inlet106 and the filter inlet 107, and passes through a replaceable filtermedia positioned in the filter cavity 110. The filter chamber 102includes two paths by which fluid may be discharged from the filterchamber 102, the filter outlet 117 and outlet 108, and the inner-chamberopening 111 that leads to the evaporator chamber 104. Since a plug 127has been placed in the filter outlet 108 in the embodiment depicted inFIG. 1, fluid is forced to flow from the filter chamber 102 into theevaporation chamber 104 through the inner-chamber opening 111.

In an embodiment in which fluid flow is desired in parallel through boththe filter chamber 102 and the evaporator chamber 104, each of thefilter inlet 107, evaporator inlet 109, and filter outlet 117 may beopened and the inner-chamber opening 111 may be plugged.

In another embodiment wherein fluid flow is desired through only thefilter chamber 102, the evaporator inlet 109, and the inner-chamberopening 111 may be plugged. Similarly, in an embodiment wherein fluidflow is desired through only the evaporator chamber 104, the filterinlet 107, the filter outlet 117, and the inner-chamber opening 111 maybe plugged.

The filter canister 112 may be configured for ease of removal from thefiltration apparatus 100 to facilitate changing filter media. Forexample, in one embodiment, the filter media is permanently sited in areplaceable, disposable filter canister 112 and the filter canister 112is screwed to the filter base 105 similar to a cap on a conventional oilfilter.

In the embodiment illustrated in FIG. 1, the inner-chamber opening 111is coupled to a perforated tube 114 that passes through a centralcylindrical opening in the filter media. In that embodiment, thefiltered fluid may flow into the perforated tube 114 through theperforations 115 and enter the evaporation chamber 104 through theinner-chamber opening 111. That inner-chamber opening 111 may be alignedwith a fluid heating channel 136 in the evaporation chamber 104 so thatflow from the filter chamber 102 into the evaporator chamber 104 isdirected through the heated space 136 formed between an inner surface138 of an evaporation tube 132 and a heater 130 described hereinafter.

The filter media may be any type of filter media desired including, forexample, paper filters, fiberglass filters, and filters made of variousmaterials that are now or may in the future be available. The filtermedia may be shaped as a cylinder having a hole in the center throughwhich the perforated tube 114 may be positioned. The filter media mayfurthermore be pleated to provide a high surface area on which tocapture particulates and may be removable and replaceable.

The filter base 105 illustrated in FIG. 1 includes a divider 116 that atleast partially separates the filter chamber 102 from the evaporationchamber 104. The filter base 105 may also include a circular wall 118that extends from the divider 116 to at least partially enclose theevaporation chamber 104. An evaporation chamber cap 120 may be attachedto the filter base 105 to cover and provide access to the evaporationchamber 104. The evaporation chamber cap 120 may be attached to thefilter base 105 as desired and may, for example, be attached by way ofscrews extending through holes 119 in the cap 120 and threaded intothreaded holes 121 formed in the circular wall 118.

The evaporation chamber cap 120 may be formed of a transparent material,such as glass or transparent or translucent plastic for ease of viewingthe operation of the evaporation chamber 104. Alternately, theevaporation chamber cap 120 may be formed of aluminum or anothermaterial for severe duty or other applications.

A threaded circular portion 122 may also extend from the divider 116opposite the circular wall 118 for attachment of the filter canister112.

The evaporator chamber 104 further includes a heater wiring inlet 134, aheater 130, an evaporation tube 132, an evaporator gas inlet 129, and anevaporator gas outlet 126. To enhance removal of airborne volatiles, anair flow stream may be created through the evaporator chamber 104through the evaporator gas inlet 129 and the evaporator gas outlet 126.For example, the evaporator gas inlet may be in fluid communication witha pressurized air source such as a turbocharger or an engine crankcase.Alternately or in addition, the evaporator gas outlet 126 may be influid communication with a vacuum air source such as a combustion airintake or an air cleaner. Fluid communication may be facilitated byconnecting tubing to the evaporator gas inlet 129 and the pressurizedair source or connecting the evaporator gas outlet 126 to the vacuum airsource.

In the embodiment illustrated in FIG. 1, the evaporation tube 132 isfitted around the heater 130 and fluid passes from the filter chamber102 into the evaporator chamber 104 through a heated space 136 formedbetween the heater 130 and an inner surface 138 of the evaporation tube132. The heated fluid then passes over an outer surface 140 of theevaporation tube 132 and volatiles, such as water and uncombusted fuel,may become gaseous and those gasses may be vented from the evaporatorchamber 104 through the evaporator gas outlet 126.

In an embodiment, the heater 130 is an electrically powered heater 130having wires 133 that pass from the heater 130, through a heater wiringopening 134 to an electrical source. In automotive applications, forexample, that electrical source may be a battery 302 or a generator 305,as illustrated in FIG. 7. Alternately, another power source may serve topower the heater 130.

FIG. 2 illustrates an embodiment of the heater 130 having a surface 144and a wire 142 wound helically along the surface 144 of the heater 130.A ridge or groove may be formed on the surface 144 of the heater 130 orthe inner surface 138 of the evaporation tube 132 rather, or in additionto using the wire 142 winding. Alternately, other shapes may be formedon the heater 130 or evaporator tube 132, or other apparatuses may beplaced between the heater 130 and the inner surface 138 of theevaporation tube 132 in any desired way to increase the duration thefluid remains proximate to or near the heater to improve fluid heating.

The evaporation tube 132 may be fitted over or around the heater 130 andits wire 142 winding, thereby creating a fluid heating channel 136between an inner surface 138 of the evaporation tube 132 and the surface144 of the heater 130 through which fluid may flow into the evaporatorchamber 104. Furthermore, the evaporation tube 132 may be fitted overthe heater 130 such that at least a portion of the fluid passing betweenthe inner surface 138 of the evaporation tube 132 and the heater 130flows along a path defined between the wire 142 windings or along theridges or grooves. Creating a narrow fluid heating channel 136 betweenthe inner surface 138 of the evaporation tube 132 and the surface 144 ofthe heater 130 promotes fluid contact with or near the surface 144 ofthe heater 130. Inclusion of grooves, ridges, or the wire 142 windingfurther promotes such contact for a longer period of time than wouldoccur if the fluid were directed between a smooth heater 130 and asmooth inner surface 138 of the evaporation tube 132. Such a prolongedexposure to the heater 130, in turn, permits greater heat transfer tothe fluid from the heater 130 as the fluid passes by the heater 130.

The heated fluid flows out from the evaporator end 147 of theevaporation tube 132 after it passes through the fluid heating channel136. FIGS. 3 and 4 depict filtration apparatuses 100 configured forimproved performance in various applications. As illustrated in FIG. 4,a splash guard 145 may be located above the evaporation tube 132 inapplications where, for example, fluid pressure in the fluid heatingchannel 136 is such that the fluid may be propelled against theevaporation chamber cap 120 or where fluid exiting the evaporation tube132 is desired to be directed by use of such a splash guard 145. Fluidflowing from the evaporation tube 132 may then flow down the outersurface 140 of the evaporation tube 132.

The evaporation tube 132 may be in contact with the divider 116 and mayfurthermore be attached to the divider 116 or formed with the divider116. The evaporation tube 132 may also be shaped variously. In oneembodiment the evaporation tube 132 has a conically shaped outer surface140 that is pinched 141 near where the evaporation tube 132 meets thedivider 116, as is illustrated in FIGS. 1, 3, and 4. The pinched portion141 of the evaporation tube 132 may have a circumference that is lessthan the circumference of the evaporation tube 132 at the widest part ofthe conical shape.

The conical shaped evaporation tube 132 outer surface 140 provides asurface that the fluid can flow along in a thin film to enhanceevaporation of volatiles. Heat may furthermore be transferred to theevaporation tube 132 from the heater 130 and the pinched portion 141 mayreduce heat transfer from the evaporation tube 132 to the divider 116and the filter base 105. The pinched portion 141 may also enhance thetransfer of volatiles from the fluid to the surrounding air by causingthe fluid to fall through the air to a fluid reservoir 152 in theevaporation chamber 104.

A safety sensor 154 may be employed in the filtration apparatus 100 tode-energize the heater 130, thus preventing the fluid from becomingoverheated. Various types of sensors 154 may be employed including, forexample, a temperature sensor (not shown) disposed in the filtrationapparatus 100 adjacent or near the fluid, a fluid flow sensor (notshown) disposed in the filtration apparatus 100 to sense fluid flow, ora pressure sensor 148 sensing fluid pressure in the filtration apparatus100. The temperature sensor may operate to de-energize the heater 130 ifthe temperature of the fluid or the filtration apparatus 100 exceeds adesired temperature. The flow sensor may operate to de-energize theheater 130 if the fluid flow rate drops below a desired flow rate. Thepressure sensor 148 may be attached directly, through tubing 155, or asdesired to a pressure sensor port 210 as described hereinafter inconnection with FIG. 5. That pressure sensor 148 may operate tode-energize the heater 130 if the fluid pressure drops below a desiredpressure, potentially indicating low fluid flow. It may be noted thatlow fluid flow could cause the temperature of the fluid in the vicinityof the heater 130 to become overheated if the heater 130 remainedenergized.

The safety sensor 154 may operate in various ways includingincorporation of an electrical contact in the safety sensor 154 throughwhich the wiring that energizes the heater 130 passes. In such anembodiment, the contact may close when it is safe to heat the fluid andthe contact may open when it is unsafe to heat the fluid. Alternately,the safety sensor 154 may be coupled to a processor 306, such as theengine control unit 308 illustrated in FIG. 7, and the heater 130 may beoperated through an output of the processor 306 such that the heater 130operates only when fluid conditions are safe for heater 130 operation.

FIG. 3 illustrates an evaporation chamber 104 having a filter base 105configured for series fluid flow through the filter chamber 102 (notshown) and the evaporator chamber 104. Fluid flows into a filter chamber102 similar to that shown in FIG. 1 through the inlet 106 and filterinlet 107. Fluid then flows from the filter chamber 102 into theevaporator chamber 104 through the inner-chamber opening 111. Afterpassing through the fluid heating channel 136, the fluid exits theevaporator chamber 104 through the outlet 108.

FIG. 4 illustrates an evaporator chamber 104 having a configurableporting arrangement and including a splash guard 145.

FIG. 5 illustrates a manifold 200 that includes a porting arrangementfor an embodiment of a filtration apparatus 100 that is similar to theporting arrangement illustrated in FIG. 4. That manifold 200 is disposedin the divider 116 between the filter chamber 102 and the evaporatorchamber 104 in the embodiment illustrated, but may be arranged otherwiseas desired. Attachment of the filtration apparatus to a mounting base,such as a housing surrounding an engine or a wall near a hydraulicexpansion tank, may be accomplished through screws threaded through themounting base into screw holes 203 in the divider 116 or otherwise asdesired.

A fluid intake port 106 extends from an outer edge 206 of the divider116 through the divider 116 to an interior cavity 207 of the filtrationapparatus 100 in which the fluid is disposed in the embodimentillustrated in FIG. 5. The fluid intake port 106 permits fluid to enterthe filtration apparatus 100 and travel along a fluid intake channel208. The fluid intake port 106 may divide into a filter inlet 107 and anevaporator inlet 109 as illustrated in FIGS. 1 and 4, or may channelfluid directly into the filter chamber 102 as illustrated in FIG. 3.

A pressure sensor port 210 extends from the fluid intake channel 208 tothe outer edge 206 of the divider 116. The pressure sensor port 210 maybe of any known type including an open port with a removable cap orplug, a type having a check valve or other arrangement that permits apressure sensor 148 to sense pressure without permitting fluid to flowout through the pressure sensor port 210, or be arranged for directattachment of a pressure sensor 148 or other sensor. The pressure sensor148 or other sensor, such as safety sensor 154, may be coupled to thepressure sensor port 210 directly, by way of a tube 155, or otherwise toactuate the sensor 148, 154.

A test sample port 212 also extends from the fluid intake channel 208 tothe outer edge 206 of the divider 116. The test sample port 212 may, forexample, include a ¼ inch test sample bore 214 having a ¼ inch testsample thread 216 extending into the divider 116 from its outer edge206. The pressure sensor port 210 may be configured similarly orotherwise as desired.

FIG. 6 illustrates an embodiment of a fluid sample valve 218 that may becoupled to the test sample port 212. The fluid sample valve 218 isthreaded to the test sample thread 216 in that embodiment. The fluidsample valve 218 may have a threaded outlet 220, and a removable testsample cap 226 may be coupled to the threaded outlet 220. The threadedoutlet 220 terminates in an outlet point 227 that can pierce a coverplaced over a test vessel, in one embodiment. In that way, clean testsamples of the fluid may be taken by removing the test sample cap 226,piercing the test vessel cover with the outlet point 227 of the fluidsample valve 218, opening the fluid sample valve 218, and permittingfluid to drain into a test vessel, for example.

In an embodiment, the test sample cap 226 may be threaded around itscircumference on a first cap end 228 to fit the test sample thread 216and hexagonal around its circumference on a second cap end 230 tofacilitate removal of the cap with a wrench. Other configurations of thecap, including use of a hexagonal depression in the end of the cap inwhich an Allen wrench may be fitted, or another desired configurationare also contemplated herein. The test sample cap 226 may also have agroove 232 around its circumference into which a snap ring 234 may beplaced and the snap ring 234 may be attached to a tether 236, such as achain or a flexible coupler made of nylon or another desired material.

Fluid samples removed from the filtration apparatus 100, through thetest sample port 212, for example, may be tested to determine whetherthey are suitable for continued use or should be replaced. Thus, thetest sample port 212 may have various uses, including serving asassurance that the fluid has the appropriate qualities and isfunctioning as desired.

Any, all, or none of the pressure sensor port 210, test sample port 212,and the fluid sample valve 218 may be provided in any desiredembodiment.

FIG. 7 illustrates an embodiment of an engine 300 incorporating afiltration apparatus 100. The engine 300 is an internal combustionengine for an automobile and the filtration apparatus 100 is for theengine 300 lubrication system in the embodiment illustrated. It shouldbe noted, however, that the filtration apparatus 100 may be used withany engine 300 and to purify any fluid.

The engine 300 includes a battery 302 and a generator 305, either ofwhich may be utilized to power the heater 130 of the filtrationapparatus 100. The engine 300 also includes a lubrication system havinga pump 304 that pumps the lubricant through the engine 300 and thefiltration apparatus 100.

FIG. 8 illustrates a hydraulic system 350 incorporating a filtrationapparatus 100 and an inlet filter 352. The hydraulic system 350 includesan expansion tank 354 having an inlet breather 356 and one or more tubes358 through which hydraulic fluid flows as required by the equipmentusing the hydraulic fluid.

Air moves into and out of the expansion tank 354 as the hydraulic tank354 level changes due, generally, to demand from the equipment using thehydraulic fluid. The inlet filter 352 is attached to the inlet breather356 by tubing 362 to clean air moving into the expansion tank 354. Suchuse of the inlet filter 352 minimizes the introduction of contaminantspresent in the air drawn into the expansion tank 354.

The filtration apparatus 100 operates as described herein to purify thehydraulic fluid. The filtration apparatus 100 may be coupled to the tankand a pump 360 may be employed to circulate hydraulic fluid through thefiltration apparatus 100. Alternately or in addition, one or morefiltration apparatuses 100 may be positioned in various locationsthroughout the hydraulic system to remove particulates and volatilesfrom the hydraulic fluid.

While the present invention has been disclosed with reference to certainembodiments, numerous modifications, alterations, and changes to thedescribed embodiments are possible without departing from the scope ofthe present invention, as defined in the appended claims. Accordingly,it is intended that the present invention not be limited to thedescribed embodiments, but that it have the full scope defined by thelanguage of the following claims, and equivalents thereof.

1. A filtration apparatus, comprising: a particulate filter section; an evaporator section positioned adjacent the particulate filter section; and a heater disposed at least in part in the evaporator section, the heater having a surface and a ridge on the surface of the heater.
 2. The filtration apparatus of claim 1, wherein the ridge includes a wire wound on the surface of the heater.
 3. The filtration apparatus of claim 1, wherein the ridge includes a ridge formed on the surface of the heater.
 4. The filtration apparatus of claim 1, wherein the ridge includes a groove formed on the surface of the heater.
 5. The filtration apparatus of claim 1, further comprising an evaporation tube positioned around the heater.
 6. The filtration apparatus of claim 5, wherein the evaporation tube includes a bore fitted adjacent the heater.
 7. The filtration apparatus of claim 5, wherein the evaporation tube has a conical shaped outer surface.
 8. A filtration apparatus, comprising: a particulate filter section; an evaporator section positioned adjacent the particulate filter section; a heater disposed at least in part in the evaporator section; and an evaporation tube positioned around the heater and having a conically shaped outer surface.
 9. The filtration apparatus of claim 8, further comprising a divider at least partially separating the particulate filter section from the evaporator section, wherein the evaporation tube contacts the divider and the evaporation tube has a reduced circumference where the evaporation tube contacts the divider.
 10. A filtration apparatus, comprising: a particulate filter section; an evaporator section positioned adjacent the particulate filter section; a heater disposed at least in part in the evaporator section; and a sensor in fluid communication with the filtration apparatus and having a switch coupled to the heater wire.
 11. The filtration apparatus of claim 10, wherein: the heater has an electrical wire that extends from the heater through the filtration apparatus; and the sensor is a pressure sensor having a switch coupled to the heater wire.
 12. A filtration apparatus, comprising: a particulate filter section; and an evaporator section positioned adjacent the particulate filter section and having an air inlet and an air outlet.
 13. The filtration apparatus of claim 12, further comprising a conduit coupled to the air inlet and a turbocharger.
 14. The filtration apparatus of claim 12, further comprising a conduit coupled to the air inlet and an engine crankcase.
 15. The filtration apparatus of claim 12, further comprising a conduit coupled to the air outlet and an air cleaner. 